Ball formed from panels with compressed edges

ABSTRACT

A sport ball comprising having a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape, an inner bladder within said shape. The sport ball of claim  1,  wherein said compressed outer edge is compressed by a factor of between one-quarter and three-quarters of said uncompressed center thickness. The compressed outer edge may be compressed approximately one-half of the uncompressed center thickness. The compressed outer edge may be compressed a width approximately equal to the uncompressed center thickness. Methods of forming the sport ball are also disclosed.

BACKGROUND OF THE INVENTION

The present invention relates to machine stitched sport balls and their manufacture. Preferably, the present invention relates to machine stitched American footballs (prolate spheroid), soccer balls, volley balls, play ground balls, handballs, etc. Most preferably, the invention relates to machine stitched soccer balls, particularly those that are suitable for professional match play.

Conventional machine stitched sport balls are formed from a plurality of panels where adjacent panels are stitched together. The panels surround and enclose an inflatable bladder. As with virtually all manufactured products, conventional machine stitched sport balls suffer from manufacturing limitations.

For example, it is difficult to provide tight stitching between adjacent panels, leaving gaps, or at least enabling gaps to form. These gaps between panels cause the cover material to prematurely tear resulting in an increase of the ball's water uptake ratio in addition to overall aesthetic degradation caused by the observable stitching and potentially, the sides of the panels. While expertly crafted hand stitched balls can limit these gaps, hand stitching requires a tremendous amount of time in addition to the labor of skilled artisans to complete a finished product.

Customer demand dictates low cost products leaving only the high rate of production with machine stitching being commercially feasible, even for professional match play where some cost tolerance can be expected.

BRIEF SUMMARY OF THE INVENTION

It would therefore be highly advantageous if machine stitched sport balls could achieve the finished quality of hand stitched sport balls while also retaining the speed and cost savings associated with machine stitching.

For this reason, a new processing method and finished ball product have been invented and developed.

In accordance with one embodiment, the invention provides for a sport ball comprising a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and an inner bladder within the shape.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and an inner bladder within the shape; wherein the compressed outer edge is compressed by a factor of between one-quarter and three-quarters of the uncompressed center thickness.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and an inner bladder within the shape; wherein the compressed outer edge is compressed approximately one-half of the uncompressed center thickness.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and an inner bladder within the shape; wherein the compressed outer edge is approximately 2.5 mm thick and the uncompressed center thickness is approximately 6 mm.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and an inner bladder within the shape; wherein the compressed outer edge is compressed a width approximately equal to the uncompressed center thickness.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and an inner bladder within the shape; wherein the compressed outer edge is compressed a width of approximately 6 mm and the uncompressed center thickness is approximately 6 mm.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and an inner bladder within the shape; wherein the panel comprises three layers, an outermost layer of synthetic leather, an innermost layer of fabric, and a middle layer of foam between the outermost and innermost layers.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball; wherein the step of embossing is accomplished with a high frequency welding machine and the compressed areas are compressed by a factor of between one-quarter and three-quarters of the uncompressed thickness.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball; wherein the step of embossing is accomplished with a high frequency welding machine and the compressed areas are compressed by a factor of between one-quarter and three-quarters of the uncompressed thickness; wherein the each of the panels has an uncompressed thickness of approximately 6 mm and a compressed thickness of approximately 2.5 mm.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball; wherein the stitching is achieved via high powered dual motor stitching machines.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball; wherein the stitching is achieved with low diameter needles.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball; wherein the step of forming forms panels with three layers, an outermost layer of synthetic leather, an innermost layer of fabric, and a middle layer of foam between the outermost and the innermost layers.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball; wherein the step of forming forms panels with three layers, an outermost layer of synthetic leather, an innermost layer of fabric, and a middle layer of foam between the outermost and the innermost layers; wherein the embossing is from the innermost layer of fabric toward the outermost layer of synthetic leather.

In a further embodiment of the invention, a method of manufacturing a sport ball comprises forming a plurality of panels having an uncompressed thickness and a continuous edge; embossing each continuous edge of each of the panels to form compressed areas; stitching the compressed areas of the panels in an arrangement to form a shape of the sport ball; and inserting a bladder within the sport ball; wherein the compressed areas have a width approximately equal to the uncompressed thickness.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and, an inner bladder within the shape; wherein the compressed outer edge is compressed by a factor of between one-quarter and three-quarters of the uncompressed center thickness; and, wherein the compressed outer edge is compressed a width approximately equal to the uncompressed center thickness.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and, an inner bladder within the shape; wherein the compressed outer edge is compressed by a factor of between one-quarter and three-quarters of the uncompressed center thickness; and, wherein the compressed outer edge is compressed a width approximately equal to the uncompressed center thickness; wherein the compressed outer edge is compressed approximately one-half of the uncompressed center thickness.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and, an inner bladder within the shape; wherein the compressed outer edge is compressed by a factor of between one-quarter and three-quarters of the uncompressed center thickness; and, wherein the compressed outer edge is compressed a width approximately equal to the uncompressed center thickness; wherein the compressed outer edge is compressed approximately one-half of the uncompressed center thickness; wherein the compressed outer edge is approximately 2.5 mm thick and the uncompressed center thickness is approximately 6 mm.

In a further embodiment of the invention, a sport ball comprises a plurality of panels, each of the panels having an uncompressed center thickness and a compressed outer edge surrounding the uncompressed center thickness, the panels being stitched together along the respective compressed outer edges to form a shape; and, an inner bladder within the shape; wherein the compressed outer edge is compressed by a factor of between one-quarter and three-quarters of the uncompressed center thickness; and, wherein the compressed outer edge is compressed a width approximately equal to the uncompressed center thickness; wherein the compressed outer edge is compressed approximately one-half of the uncompressed center thickness; wherein the compressed outer edge is approximately 2.5 mm thick and the uncompressed center thickness is approximately 6 mm; wherein the compressed cuter edge is compressed a width of approximately 6 mm.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with features, objects, and advantages thereof, will be or become apparent to one with skill in the art upon reference to the following detailed description when read with the accompanying drawings. It is intended that any additional organizations, methods of operation, features, objects or advantages ascertained by one skilled in the art be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.

With respect to the drawings, FIG. 1 shows a side view of a compound material sheet used to form panels used in the manufacture of the inventive balls;

FIG. 2 shows a side perspective view of a hexagonal panel used in manufacture of the inventive balls, the panel being shown prior to edge compression;

FIG. 3 shows a bottom view of the panel of FIG. 2 following edge compression;

FIG. 4 shows a photograph of a pentagonal panel used in the manufacture of inventive balls, also following edge compression;

FIG. 5 shows a side perspective view of a pentagonal panel used in the manufacture of inventive balls, again following edge compression;

FIG. 6 is a magnified photograph detailing two adjacent soccer hall panels stitched together using the inventive techniques shown and described herein; and,

FIG. 7 shows a perspective view of soccer ball manufactured using the inventive techniques shown and described herein.

DETAILED DESCRIPTION

In the following are described the preferred embodiments of the BALL FORMED FROM PANELS WITH COMPRESSED EDGES in accordance with the present invention. In describing the embodiments illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. Where like elements have been depicted in multiple embodiments, identical reference numerals have been used in the multiple embodiments for ease of understanding.

The sport balls of the present invention, and particularly the panels from which they are formed, may be manufactured from many different materials. In a preferred embodiment, the panels of a sport ball may comprise three distinct components adhered in layers to form a compound cover material (synthetic leather+foam+fabric). This compound cover material, such as the material shown in FIG. 1, may be formed into sheets 100. In one example, the sheet 100 includes an innermost layer 102, which one will appreciate is to be positioned adjacent to the bladder upon manufacture. Innermost layer 102 is comprised of a fabric material. Suitable fabric materials include natural and synthetic polyester fibers.

The sheet 100 also includes an outermost layer 104 which is visible upon manufacture of the sport ball and forms the visible layer or even what most consumers would consider to be the “ball.” This outermost layer 104 may be comprised of synthetic leather, typically bicast leather (also referred to as bycast leather, bi-cast leather, or PU leather). It will be appreciated that bicast leather is itself a multi-layer product, consisting of a split leather backing covered with polyurethane. The outermost layer may also be comprised of thermoplastic polyurethane (TPU) or flexible polyvinyl chloride.

Between the innermost layer 102 and outermost layer 104 is a middle layer 106 preferably formed from foam. Suitable foam materials include synthetic polymers such as ethylene vinyl acetate, thermoplastic elastomer and polyolefin, etc.

To form the panel 100, the outermost layer 104 is laminated on the middle layer 106 using an adhesive. Suitable adhesives for this portion include natural latex adhesives. The innermost layer 102 is then attached to the foam side of the laminated middle layer 106 using an adhesive. Suitable adhesives for this portion include latex adhesives. This procedure may also be conducted in reverse with the innermost layer 102 being attached to the middle layer 106 prior to the outermost layer 104 being laminated on the middle layer 106.

The total thickness of panel 100 is preferably 6 mm with a suitable range being approximately 5 mm to 7 mm. In preferred embodiments, the outermost layer 104 is 1 mm thick, the middle layer 106 is 4.5 mm thick, and the innermost layer 102 is 0.5 mm thick. It will, however, be appreciated that the outermost layer 104 may typically range from 0.07 mm to 2 mm in thickness and the middle layer 106 may typically range from 3 mm to 5 mm. The innermost layer 102 typically ranges from 0.3 mm to 0.8 mm.

Once formed, the sheet 100 is cut into multiple panels with sizes and configurations dictated by the design of the finished product. A cutting machine may be used for this purpose. Suitable panel configurations include geometric and non-geometric shapes.

Shown in FIG. 2 is an exemplary panel 200 in the form of a hexagonal panel. As shown, the panel 200 is planar and includes the innermost layer 202, middle layer 206, and outermost layer 204. To form the inventive sport balls, portions of the panel 200 are embossed to form locally compressed areas.

FIG. 3 shows a bottom view of panel 200 of FIG. 2 following embossment of the edge portions of the panel, also referred to as edge compression. Here, the panel 200 is embossed a distance (width of the compressed area) from its outermost edge 208 toward its geometric center 210 (shown as a dot for reference purposes) approximately equal to the overall thickness of the panel 200. In this example the panel 200 is therefore embossed a dimension “A” approximately 6 mm from its outermost, edge 208 toward the geometric center 210. In preferred embodiments, both the thickness of the panel 200 and this dimension “A” is between 5 mm and 7 mm. In other embodiments, the embossed distance (width of compressed area) can differ considerably from the overall thickness of the panel 200.

As will be discussed, the embossing procedure typically reduces the overall panel thickness in the embossed region, thereby creating a compressed area, by a factor of one-quarter to three-quarters, with approximately one-half being common.

To achieve edge compression, the panel 200 is embossed from the innermost layer 202, a fabric layer, through the use of a high frequency welding machine or other means. The entire length of the outmost edge 208 is embossed, and due to this process, the outermost edge becomes stiff and hard. This stiffness provides an important function in finished product quality, particularly with respect to the avoidance of panel tearing.

For reference, a photograph of an embossed panel 400 is shown in FIG. 4. One will appreciate that this panel 400 is pentagonal in shape and includes an embossed area 402.

FIG. 5 shows a side view of panel 400, with an indication of the “B” dimension representing the overall thickness of the panel and the “C” dimension representing the post embossment thickness of the compressed area 402. In preferred embodiments, dimension “B” is 6 mm and dimension “C” is 2.5 mm. In other embodiments, dimension “B” is between 5 mm and 7 mm and dimension “C” ranges from one-quarter to three-quarters of dimension “B.”

After completing the panel embossing, the panels are stitched together (per design artwork to form a, commonly spherical or prolate spheroid, ball) by using high powered dual motor stitching machines to ensure extra strength in the stitching. High force with close switching is used to avoid any open stitches which tend to compromise product quality. Also, commonly used are special low diameter needles. These needles help to avoid water uptake problems by ensuring that the stitch pore area remains small. Before complete stitching of the panels forming the cover material, the winded or patched bladder is inserted and fixed into the shell by using an adhesive. The stitching process is then completed. Optionally, the ball may then put into molding process for approximately one minute with specific temperature and pressure as per the properties of top material.

FIG. 6 is a magnified photograph detailing two adjacent soccer ball panels stitched together using the inventive techniques shown and described herein. As shown in FIG. 6, two adjacent panels 600, 602 are stitched together along a stitch line 604 which provides much smaller stich pores (not shown) than conventional stitching methods while also positioning the panels 600, 602 in very close proximity to each other, a proximity that can be maintained for much longer periods of time in use than balls manufactured using conventional methods.

In conventional machine stitched balls, the cover material, which is typically 3 mm to 4.5 mm in thickness, is stitched on simple machines without extra force or prior embossing. The result is a low-quality ball in terms of stitching and other issues as mentioned earlier. Due to these problems, such a ball does not have potential to play its part as an official match ball.

FIG. 7 shows a perspective view of soccer ball 700 manufactured using the inventive techniques shown and described herein. As shown, the ball 700 includes pentagonal panels 702 as well as hexagonal shaped panels 704. Other configurations, be they geometric or non-geometric, are also possible. While soccer ball 700 is a machine stitched ball, because of the inventive techniques, the soccer ball is entirely suitable for match play.

Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. 

1. A sport ball comprising: a plurality of panels, each of said panels having an uncompressed center thickness and a compressed outer edge surrounding said uncompressed center thickness, said panels being stitched together along said respective compressed outer edges to form a shape; and, an inner bladder within said shape.
 2. The sport ball of claim 1, wherein said compressed outer edge is compressed by a factor of between one-quarter and three-quarters of said uncompressed center thickness.
 3. The sport ball of claim 1, wherein said compressed outer edge is compressed approximately one-half of said uncompressed center thickness.
 4. The sport ball of claim 1, wherein said compressed outer edge is approximately 2.5 mm thick and said uncompressed center thickness is approximately 6 mm.
 5. The sport ball of claim 1, wherein said compressed outer edge is compressed a width approximately equal to said uncompressed center thickness.
 6. The sport ball of claim 1, wherein said compressed outer edge is compressed a width of approximately 6 mm and said uncompressed center thickness is approximately 6 mm.
 7. The sport ball of claim 1, wherein said panel comprises three layers, an outermost layer of synthetic leather, an innermost layer of fabric, and a middle layer of foam between said outermost and innermost layers. 8-15. (canceled)
 16. A sport ball comprising: a plurality of panels, each of said panels having an uncompressed center thickness and a compressed outer edge surrounding said uncompressed center thickness, said panels being stitched together along said respective compressed outer edges to form a shape; and, an inner bladder within said shape; wherein said compressed outer edge is compressed by a factor of between one-quarter and three-quarters of said uncompressed center thickness; and, wherein said compressed outer edge is compressed a width approximately equal to said uncompressed center thickness.
 17. The sport ball of claim 16, wherein said compressed outer edge is compressed approximately one-half of said uncompressed center thickness.
 18. The sport ball of claim 17, wherein said compressed outer edge is approximately 2.5 mm thick and said uncompressed center thickness is approximately 6 mm.
 19. The sport ball of claim 18, wherein said compressed outer edge is compressed a width of approximately 6 mm.
 20. The sport ball of claim 1, wherein said compressed outer edge is accomplished with a high frequency welding machine.
 21. The sport ball of claim 20, wherein said compressed outer edge is formed prior to stitching.
 22. The sport ball of claim 16, wherein said compressed outer edge is accomplished with a high frequency welding machine.
 23. The sport ball of claim 22, wherein said compressed outer edge is formed prior to stitching. 